Switch assembly and methods of use

ABSTRACT

Various implementations include a switch assembly that includes a housing and at least two printed circuit boards (PCBs) that are disposed within the housing and are axially arranged relative to each other. One or more force sensors are disposed on one of the PCBs, and, in some implementations, the one or more force sensors receive force input received by a touch overlay plate. Signals from the force sensors are processed to determine a magnitude, acceleration, and/or location of the force input, and a haptic feedback response is received by the touch overlay plate. The haptic feedback response is based on the force magnitude, acceleration, and/or location of input, according to some implementations. Axially arranging the PCBs reduces the footprint of the switch assembly and allows for the inclusion of more electrical components in the switch assembly, according to some implementations.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. patentapplication Ser. No. 16/916,430 filed Jun. 30, 2020, which will issue asU.S. Pat. No. 11,281,322 on Mar. 22, 2022, which claims priority to andbenefit of U.S. patent application Ser. No. 15/861,986 filed Jan. 4,2018, which issued as U.S. Pat. No. 10,707,034 on Jul. 7, 2020, whichclaims priority to and benefit of U.S. Provisional Patent ApplicationNo. 62/442,306 filed Jan. 4, 2017, each of which are fully incorporatedby reference and made a part hereof.

BACKGROUND

Conventional capacitive sense touchscreen technologies, such as thoseused in smartphones and tablet devices, require significant visualengagement by a driver, which is a distraction for the driver andcompromises safety. Conventional mechanical switches and knobs are lessdistracting because they can be safely used without requiring the driverto remove his eyes from the road, but they tend to have limitedflexibility, with each switch controlling a single function or feature.

Thus, there is a need in the art for a switch assembly that providessufficient feedback to the driver upon receiving driver input to avoiddistracting the driver and that provides the ability to control multiplefunctions and/or vehicle systems with a minimal footprint.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become apparent from the following description and theaccompanying exemplary implementations shown in the drawings, which arebriefly described below.

FIG. 1 illustrates a perspective view of a switch assembly according toone implementation.

FIG. 2 illustrates an exploded view of part of the switch assembly shownin FIG. 1 .

FIG. 3 illustrates a cross sectional view of a partially assembledswitch assembly as taken through the C-C line in FIG. 1 .

FIG. 4 illustrates a perspective view of the haptic exciter shown inFIG. 2 .

FIG. 5 illustrates a perspective view of the housing shown in FIG. 2 .

FIG. 6 illustrates a perspective view of the switch assembly shown inFIG. 2 partially assembled.

FIG. 7 illustrates a perspective view of the second surface of the firstPCB shown in FIG. 2 .

FIG. 8 illustrates a perspective view of the second surface of thesecond PCB shown in FIG. 2 .

FIG. 9A illustrates a perspective view of the second surface of thelight guide shown in FIG. 2 .

FIG. 9B illustrates a perspective view of the first surface of the lightguide shown in FIG. 2 .

FIG. 9C illustrates a cross sectional view of the light guide shown inFIG. 2 .

FIGS. 10A and 1013 illustrate perspective views of the annular frameshown in FIG. 2 .

FIG. 11 illustrates a perspective view of the membrane shown in FIG. 2 .

FIG. 12 illustrates a plan view of the first surface of the touchoverlay plate shown in FIG. 1 .

FIG. 13 illustrates perspective view of a first surface of a light guideaccording to another implementation.

FIG. 14 illustrates a block diagram of an electrical control systemaccording to one implementation.

FIG. 15 illustrates a flow diagram of instructions stored on a memoryfor execution by a processor disposed on the second PCB, according toone implementation.

FIG. 16 illustrates a flow diagram of instructions stored on a memoryfor execution by a processor disposed on the first PCB, according to oneimplementation.

FIG. 17 illustrates a graph of a resistance sensed by the force sensorsand a corresponding force signal associated with each resistance level,according to one implementation.

FIGS. 18A-18D illustrate exemplary touch events and a correspondinghaptic response to each touch event, according to one implementation.

FIG. 19A illustrates a perspective view of a portion of a switchassembly according to another implementation.

FIG. 19B illustrates a cross sectional view of the portion of the switchassembly shown in FIG. 19A as taken through the D-D line.

FIG. 19C illustrates an exploded view of the portion of the switchassembly shown in FIG. 19A.

FIG. 20A illustrates a perspective view of a portion of a switchassembly according to another implementation.

FIG. 20B illustrates a cross sectional view of the portion of the switchassembly shown in FIG. 20A as taken through the E-E line.

FIG. 20C illustrates an exploded view of the portion of the switchassembly shown in FIG. 20A.

FIG. 20D illustrates a perspective view of a portion of the switchassembly shown in FIG. 20A.

DETAILED DESCRIPTION

Various implementations include a switch assembly that includes ahousing and at least two printed circuit boards (PCBs) that are disposedwithin the housing and are axially arranged relative to each other. Oneor more force sensors are disposed on one of the PCBs, and, in someimplementations, the one or more force sensors receive force inputreceived by a touch overlay plate. Signals from the force sensors areprocessed to determine a magnitude, acceleration, and/or location of theforce input, and a haptic feedback response is received by the touchoverlay plate. The haptic feedback response is based on the forcemagnitude, acceleration, and/or location of input, according to someimplementations. Axially arranging the PCBs reduces the footprint of theswitch assembly and allows for the inclusion of more electricalcomponents in the switch assembly, according to some implementations.

Various implementations are described in detail below in accordance withthe figures.

For example, FIGS. 1-12 illustrate a switch assembly according to oneimplementation. The switch assembly 100 includes a housing 102, a firstprinted circuit board (PCB) 110, a second PCB 112, a light guide 142, amembrane 170, an optional touch overlay plate 195, and an annular frame180.

The housing 102 has a first wall 104 and a second wall 106 that define achamber 108. The second wall 106 extends axially from a radial outeredge 105 of the first wall 104, forming a side wall. A distal edge 172of the second wall 106 defines an opening to the chamber 108.Longitudinal axis A-A extends through a center of the chamber 108 andthe first wall 104.

Two or more PCBs are arranged axially adjacent each other within thechamber 108. In particular, a first PCB 110 is disposed within thechamber 108 adjacent the first wall 104, and a second PCB 112 is axiallyadjacent and spaced apart from the first PCB 110 within the chamber 108.A first electrical connector 114 extends from a second surface 116 ofthe first PCB 110, and a second electrical connector 117 extends from afirst surface 118 of the second PCB 112. These electrical connectors114, 117 are axially aligned and coupled together to allow electricalcommunication between the PCBs 110, 112. The first PCB 110 also includesa third electrical connector 120 extending from a first surface 122 ofthe first PCB 110. The third electrical connector 120 is electricallycoupled with a vehicle communication bus, for example. In theimplementation shown, the third electrical connector 120 is axiallyarranged relative to the first electrical connector 114, but theconnectors 120, 114 are not axially aligned. However, in otherimplementations, the third electrical connector 120 is axially alignedwith the first electrical connector 114.

The first wall 104 of the housing includes a first set of one or moreprojections 125 that extend inwardly into the chamber 108 in thedirection of axis A-A. The first surface 122 of the first PCB 110 isdisposed on a distal surface 125 a of the first set of one or moreprojections 125 such that the first surface 122 is spaced apart from thefirst wall 104. The first PCB 110 defines openings 124, and the firstset of projections 125 define openings 126 that are axially aligned withopenings 124. A fastener 127 is engaged through respective pairs ofaligned openings 124, 126 to couple the first PCB 110 to the projections125 and prevent relative movement of the first PCB 110 within thechamber 108. Although three fasteners are shown, more or less fastenersmay be selected. In other implementations, other fastening arrangementsmay be selected. For example, other fastening arrangements include afriction fit within the housing, snaps, clips, rivets, adhesive, orother suitable fastening mechanism.

A second set of projections 128 extend axially inwardly into the chamber108 from the first wall 104 and radially inwardly into the chamber 108(e.g., in a direction perpendicular to and toward the axis A-A) from thesecond wall 106. The second set of projections 128 are spaced apart fromeach other. As shown in FIG. 5 , each projection 128 includes a firstrib 132 and a second rib 134. Each rib 132, 134 includes a proximal edge133 that is coupled to the second wall 106 and a distal edge 135 that isspaced radially inwardly into the chamber 108 from the proximal edge133. The distal edges 135 of ribs 132, 134 intersect and define a boss136. Projections 125 extend between projections 128, but the surface 125a of each projection 125 is spaced apart from a surface 130 of eachprojection 128. In particular, a plane that includes surface 125 a isspaced axially between the first wall 104 and a plane that includessurface 130. The first surface 118 of the second PCB 112 is disposed onthe surfaces 130 of projections 128 such that openings 138 defined inthe second PCB 112 are axially aligned with openings defined by thebosses 136. Fasteners 137 extend through each pair of aligned openings138, 136 to couple the second PCB 112 to the projections 128 and preventrelative movement of the second PCB 112 within the chamber 108. Althoughfour fasteners are shown, more or less fasteners may be selected. Inother implementations, other fastening arrangements may be selected. Forexample, other fastening arrangements include a friction fit within thehousing, snaps, clips, rivets, adhesive, or other suitable fasteningmechanism.

The first PCB 110 has an outer perimeter that is shaped to fit withinthe chamber 108 and between the second set of projections 128, whichallows the first surface 122 of the first PCB 110 to be disposed on thesurface 125 a of projections 125. The second PCB 112 also has an outerperimeter that is shaped to fit within the chamber 108 such that thefirst surface 118 of the second PCB 112 engages the ribs 132, 134 of thesecond set of projections 128.

A plurality of force sensors 140 are disposed on the second surface 123of the second PCB 112 and are spaced apart from each other. The forcesensors 140 are axially aligned with respective first ribs 132 and/orsecond ribs 134. This arrangement allows force to be applied in thez-direction (i.e., along central longitudinal axis A-A) toward the forcesensors 140, and the surfaces 130 of the projections 128 prevent thesecond PCB 112 from bending or flexing where the force sensors 140 arecoupled to the second PCB 112 in response to the force applied, whichprevents the force sensors 140 from being damaged. The surfaces 130 ofthe projections 128 also prevent axial movement of the second PCB 112relative to the first PCB 110 and the housing 102 when force is receivedby the force sensors 140. In one implementation, the force sensors 140comprise micro electro-mechanical sensors (MEMS) that provide an outputsignal that corresponds with an amount of force received by the sensors.For example, the MEMS force sensors are able to detect force with aslittle as 2 microns of displacement.

The light guide 142 is disposed within the chamber 108 and includes afirst surface 144, a second surface 143 that is opposite and spacedapart from the first surface 144, and a side edge 145 that extendsbetween the first surface 144 and the second surface 143. The firstsurface 144 of the light guide 142 faces the force sensors 140 coupledto the second PCB 112. The light guide 142 is a plate made from atransparent or translucent material. For example, the light guide 142may comprise a rigid material, such as acrylic or a polycarbonatematerial. At least one light source is disposed on the second surface123 of the second PCB 112. For example, in some implementations, thelight source includes a light emitting diode (LED) 146, and the sideedge 145 of the light guide 142 is disposed radially adjacent the LED146. Light from the LED 146 travels through the side edge 145 of thelight guide 142 and exits from the second surface 143 of the light guide142. With this system, a single light source or multiple light sourcesare disposed on the same side, adjacent sides, or opposing sides of thelight guide 142, and the light is directed toward the second surface 143of the light guide 142. However, in other implementations, the light mayenter the light guide 142 through the first surface 144 of the lightguide 142.

In some implementations, the second surface 143, first surface 144,and/or side edge 145 of the light guide 142 include integrally formedmicro-lenses to direct light through the light guide 142 and out of thesecond surface 143. For example, FIG. 9C illustrates a plurality ofmicro-lenses 147, which include protrusions and/or recessed portions, onthe first surface 144 of the light guide 142. In other or furtherimplementations, one or more light altering films are disposed on one ormore of the light guide surfaces 143, 144 and/or side edge 145 of thelight guide 142.

In the implementation shown in FIG. 9B, the first surface 144 of thelight guide 142 includes a plurality of protrusions 148 that extendaxially from the first surface 144. The protrusions 148 axially alignwith the force sensors 140 on the second PCB 112. The protrusions 148concentrate the force received by the light guide 142 onto the forcesensors 140. In one implementation, the protrusions 148 are integrallyformed with the first surface 144. However, in other implementations,the protrusions 148 may be formed separately and coupled to the firstsurface 144.

In another implementation shown in FIG. 13 , the first surface 144′ ofthe light guide 142′ is planar, and a force concentrator that isseparately formed from the light guide 142′ is disposed between eachforce sensor and the first surface 144′ of the light guide 142′. Eachforce concentrator transfers force received by the light guide 142′ tothe respective force sensor below the force concentrator.

The haptic exciter 160 provides haptic feedback to a user. For example,according to one implementation, the haptic exciter 160 is a speaker(e.g., a coneless voice coil assembly), and the haptic output is anaudible or inaudible sound wave that changes the air pressure near anoutput surface of the speaker by propagating a plurality of pressurewaves along an axis of propagation. The propagation axis isperpendicular to an output surface 161, and in the implementation shown,is parallel to central axis A-A, which extends orthogonally to andthrough the surfaces 196, 197 of the touch plate 195. For example, thepropagation axis may be co-axial with axis A-A in some implementations.In the implementation shown in FIGS. 1-12 , the output surface 161 ofthe haptic exciter 160 is coupled directly to the first surface 144 ofthe light guide 142. Thus, at least a portion of the pressure wavespropagated from the output surface 161 are directed toward and arecaptured by the first surface 144 of the light guide 142, which causesvibration, or oscillation, of the light guide 142 in the z-direction. Inthis implementation, the first surface 144 of the light guide 142 servesas the reaction surface for the exciter 160. The vibration of the lightguide 142 is transferred to the membrane 170 and to the touch plate 195.Thus, the haptic exciter 160 is vibrationally coupled to the innersurface 196 of the touch plate 195 because pressure waves originatingfrom the haptic exciter 160 induce a vibratory response on the touchplate 195. In some implementations, the haptic exciter 160 is coupled tothe first surface 144 of the light guide 142 using an adhesive 162.However, in other implementations, other suitable fastening mechanismsmay be used. And, in other implementations, the output surface 161 ofthe haptic exciter 160 is disposed axially adjacent and spaced apartfrom the first surface 144 of the light guide 142. In addition, in someimplementations, the haptic exciter 160 is disposed adjacent a centralportion of the first surface 144 of the light guide 142.

As shown in FIG. 4 , the haptic exciter 160 includes a flexible cableconnector 164 that has a first end 165 that is coupled to a first end166 of the haptic exciter 160 and a second end 167 that is coupled tothe first surface 118 of the second PCB 112. The flexible cableconnector 164 minimizes or eliminates transmission of the vibration fromhaptic exciter 160 to the second PCB 112 while allowing the hapticexciter 160 to be electrically coupled to the second PCB 112. In onenon-limiting example, the flexible cable connector may be a zeroinsertion force (ZIF)-type connector. In alternative implementations,the haptic exciter 160 is coupled to the second PCB 112 with wires thatare coupled to each via soldering or other suitable coupling mechanism.

In addition, the second PCB 112 defines an opening 163 through which theoutput surface 161 of the haptic exciter 160 extends for coupling theoutput surface 161 to the first surface 144 of the light guide 142. Thisarrangement allows the height in the direction of axis A-A of the switchassembly 100 to be reduced, increases the energy received by the touchoverlay 195 from the haptic exciter 160, and reduces the vibrationalenergy transferred to the second PCB 112. However, in otherimplementations, the second PCB 112 may not define opening 163, and thehaptic exciter 160 may be axially spaced apart from the second surface123 of the second PCB 112 and disposed between the first surface 144 ofthe light guide 142 and the second surface 123 of the second PCB 112. Byspacing the haptic exciter 160 apart from the second PCB 112, thevibrational energy from the haptic exciter 160 is isolated from thesecond PCB 112, which allows more of the energy to be received by thelight guide 142.

The flexible membrane 170 extends over at least a portion of the chamber108. A first surface 171 of the flexible membrane 170 faces the secondsurface 143 of the light guide 142, and at least a portion of thesesurfaces 171, 143 are coupled together (e.g., by adhesion). A pluralityof posts 173 extend axially from the distal edge 172 of the second wall106 of the housing 102 and are circumferentially spaced apart from eachother. The flexible membrane 170 defines a plurality of post openings174 adjacent a radially outer edge 175 of the membrane 170. The posts173 are engaged through respective post openings 174 of the membrane 170to prevent movement of the membrane 170 in the x-y plane (i.e., planeperpendicular to the central axis A-A). In some implementations, thesurfaces 171, 143 are coupled together prior to the posts 173 beingengaged through the openings 174. By limiting the movement of themembrane 170 to the z-direction, the membrane 170 is able to transferthe vibration from the light guide 142 more efficiently, and themembrane 170 can prevent an x- or y-component of force incident on theswitch assembly 100 from being transferred to the force sensors 140,which prevents damage to the force sensors 140 due to shear forces. Themembrane 170 may also prevent ingress of fluids or debris into theswitch 100.

In the implementation described above, the membrane 170 covers theopening of the chamber 108, but in other implementations, the membrane170 may only cover a portion of the opening of the chamber 108.

The membrane 170 is formed of a flexible material that is capable ofresonating in the z-direction. For example, the membrane 170 may be madeof a polymeric material (e.g., polyester, polycarbonate), a thin metalsheet, or other suitable flexible material. In addition, the stiffnessof the material for the membrane 170 may be selected based on the amountof resonance desired and in consideration of the load to be incident onthe membrane 170.

The touch overlay plate 195 has a first surface 196 and a second surface197. At least a central portion 201 of the first surface 196 of thetouch overlay plate 195 is coupled to a second surface 198 of membrane170, and the second surface 197 of the touch overlay plate 195 faces inan opposite axial direction from the first surface 196 and receivesforce input from the user. For example, in one implementation, thesecond surface 198 of the membrane 170 and the central portion 201 ofthe first surface 196 of the touch overlay plate 195 are adheredtogether.

In some implementations, at least a portion of the second surface 197 ofthe touch overlay plate 195 is textured differently than the portion ofthe vehicle adjacent to the switch assembly 100 to allow the user toidentify where the touch overlay plate 195 is in the vehicle withouthaving to look for it. And, in some implementations, as shown in FIG. 3, the second surface 197 includes a non-planar surface. For example, thecontour of the non-planar surface may be customized based on variousapplications of the assembly and/or to facilitate the user locating thesecond surface 197 without having to look for it.

In some implementations, icons are disposed on the touch overlay plate195, and light exiting the second surface 143 of the light guide 142passes through the membrane 170 and the icons on the touch overlay plate195 to illuminate the icons. For example, by providing icons on a sheetthat is adhesively coupled to the touch overlay plate 195, the icons areeasily customizable for each vehicle manufacturer, and the switchassembly 100 is manufactured efficiently.

In some implementations, the flexible membrane 170 oscillates in thez-direction in response to receiving vibrational energy from the hapticexciter 160 via the light guide 142, and this oscillation is transferredto the touch overlay plate 195 to provide the haptic feedback to theuser. Furthermore, the haptic response of the switch assembly 100 istunable by selecting a light guide 142, membrane 170, and touch overlayplate 195 that together have a certain stiffness.

In addition, to isolate the vibration of the light guide 142 and touchoverlay plate 195 from the housing 102 and PCBs 110, 112 and to ensurethat the light guide 142 and touch overlay plate 195 do not rotate aboutthe central axis A-A, an interlocking mechanism is employed to couplethe light guide 142 and the touch overlay plate 195, according to someimplementations. For example, as shown in FIGS. 3, 6, 9A, 11, and 12 ,the second surface 143 of the light guide 142 defines a second set ofprotrusions 157 that extend axially away from the second surface 143.The second set of protrusions 157 includes two or more protrusions, andthe protrusions 157 are spaced apart from each other. The protrusions157 are disposed radially inward of and adjacent the side edge 145 ofthe light guide 142. The flexible membrane 170 defines openings 158through which the protrusions 157 extend. And, the first surface 196 ofthe touch overlay plate 195 defines recessed portions 159 that extendaxially into the first surface 196. Distal ends of the protrusions 157extend and are seated within the recessed portion 159. In theimplementation shown in FIGS. 9A and 12 , there are four recessedportions 159 defined in the touch overlay plate 195 and threeprotrusions 157 extending from the second surface 143 of the light guide142. Having one or more additional recessed portions 159 allows parts tobe standardized such that they can be used in different areas of thevehicle (e.g., left side or right side). However, in otherimplementations, the interlocking mechanism may include one or moreprotrusions and recessed portions.

In some implementations, a portion or all of the touch overlay plate 195is comprised of a transparent or translucent material allows light topass through the touch overlay plate 195. For example, the touch overlayplate 195 may comprise a piece of clear, contoured glass. Othertransparent or translucent materials can be used, including othercrystal materials or plastics like polycarbonate, for example. In someimplementations the contoured nature of one side, the second side 197,of the touch overlay plate 195 allows the user to move around theirfinger to find the right button location without having to initiate theswitch past the force threshold.

The annular frame 180 includes an annular wall 181 and a side wall 182that extends axially from adjacent an outer radial edge 183 of theannular wall 181. The annular wall 181 includes an inner radial edge 184that defines an opening 185 having a central axis B-B. The annular wall181 also defines one or more post openings 186 between the inner radialedge 184 and the outer radial edge 183. The annular frame 180 is coupledto the second wall 106 of the housing 102. When coupled together, aninner surface 187 of the side wall 182 is disposed adjacent an outersurface 107 of the second wall 106. A portion of the membrane 170adjacent the outer radial edge 175 of the membrane 170 is disposedbetween the annular wall 181 and the distal edge 172 of the second wall106. Posts 173 are engaged through openings 174 defined in the membrane170 and within respective post openings 186 of annular wall 181 toprevent movement in the x-y plane of the annular frame 180 relative tothe housing 102. When coupled, the axis B-B of the annular frame 180 iscoaxial with axis A-A of the housing 102. In the implementation shown,at least a portion of the outer radial edge 175 of the membrane 170folds over the distal edge 172 of the second wall 106 and is disposedbetween the inner surface 187 of side wall 182 of the annular frame 180and the outer surface 107 of the second wall 106. Furthermore,protrusions 157 are disposed radially inward of the inner radial edge184 of the annular wall 181 when the annular frame 180 is coupled to thehousing 102.

Fastener openings 188 are defined in the annular wall 181, and fasteneropenings 177 are defined by the second wall 106 of the housing 102.Fasteners 189 are engaged through aligned pairs of openings 188, 177 tocouple the annular frame 180 to the housing 102. For example, in theimplementation shown in FIGS. 1-12 , the annular wall 181 includesradial extensions 181 a that extend radially outwardly from the wall 181and define the fastener openings 188. And, radial extensions 106 aextend radially outwardly from the wall 106 and define fastener openings177. However, in other implementations, the annular frame 180 is coupledto the housing 102 using other fastening arrangements. For example, insome implementations, the annular frame 180 is coupled to the housing102 via fasteners extending through the side wall 182 of the annularframe 180 and the outer surface 107 of the second wall 106 of thehousing 102. In other implementations, the annular frame 180 is coupledto the housing 102 using a friction fit, snaps, clips, rivets, adhesive,or other suitable fastening mechanism.

In certain implementations, one or more springs are disposed between theannular wall 181 of the annular frame 180 and the light guide 142 tourge the light guide 142 toward the second surface 123 of the second PCB112. By disposing one or more springs between the annular wall 181,which is fixedly coupled to the housing 102, and the light guide 142,the one or more springs pre-load the force sensors 140. For example, theone or more springs may pre-load the force sensors to between 1 and 5 N.In one non-limiting example, the one or more springs pre-load the forcesensors to 2.8 N. For example, in the implementation shown in FIGS. 1-12, the springs include coil springs 190 that extend between a firstsurface 205 of the annular wall 181 and the second surface 143 of thelight guide 142. Axial depressions 206 are defined in a recessed portion207 defined by the second surface 143 of the light guide 142 and theside edge 145 of the light guide 142. The recessed portions 207 have asurface that is axially spaced apart from the second surface 143 of thelight guide 142 in a direction toward the first surface 144 of the lightguide 142. Inward radial extensions 204 extend radially inwardly fromthe inner radial edge 184 of the annular wall 181. The inward radialextensions 204 also define axial depressions 306 according to someimplementations. The axial depressions 306 defined by the inward radialextensions 204 are axially aligned with the axial depressions 206defined by the light guide 142, and ends of each spring 190 seats in therespective axially aligned axial depression 306 of the inward radialextension 204 and the axial depression 206 of the light guide 142 toprevent movement of the coil spring 190 in the x-y plane. In addition,the membrane 170 defines spring recesses 178 that extend radiallyinwardly from the outer radial edge 175 of the membrane 170, and thesprings 190 extend through the recesses 178 and are spaced apart fromthe outer radial edge 175 of the membrane 170 so as not to interferewith the oscillation of the membrane 170.

In the implementation shown in FIGS. 19A-19C, the springs are leafsprings 290. The leaf springs 290 include a central portion 291 and legportions 292 a, 292 b. Leg portions 292 a, 292 b extendcircumferentially from and radially inwardly from the central portion291. The second surface 243 of the light guide 242 includes a pluralityof posts 293 that extend axially away from the second surface 243, andthe membrane 270 defines openings 279 through which the posts 293extend. The central portion 291 of each leaf spring 290 is coupled tothe first surface 255 of the annular wall 281 of the annular frame 280,and the leg portions 292 a, 292 b engage distal ends 294 of posts 293.When assembled, a plane that includes the first surface 255 of theannular wall 281 to which the central portion 291 of the leaf spring 290is coupled is axially between a plane that includes the distal ends 294of the posts 293 and a plane that includes the second surface 243 of thelight guide 242. Thus, the leg portions 292 a, 292 b of the leaf spring290 are biased toward the light guide 242 and urge the first surface 244of the light guide 242 toward the second PCB 112. It is to beappreciated that the posts 293 may be separately formed from the lightguide 242, or they can be integrally formed with the light guide 242.

FIG. 19B also shows a second set of protrusions 257, which are similarto the second set of protrusions 157 shown in FIGS. 3, 6, 9A, 11, and 12, that extend axially away from the second surface 243 of the lightguide 242. The second set of protrusions 257 includes three protrusions,and the protrusions 257 are spaced apart from each other. Theprotrusions 257 are disposed radially inward of and adjacent the sideedge 245 of the light guide 242. Like the protrusions 157 describedabove, the protrusions 257 extend through openings in the membrane andinto recessed portions defined by the first surface of the touchoverlay.

FIGS. 20A-20D illustrate leaf spring 390 according to anotherimplementation. In this implementation, the leaf spring 390 includes acentral portion 391 and leg portions 392 a, 392 b that extendcircumferentially from and radially inwardly from the central portion391. Each leg portion 392 a, 392 b also includes an arcuate portion 393having an apex 394 that is within a plane that is spaced apart from aplane that includes the central portion 391. The central portion 391 iscoupled to the first surface 355 of an annular wall 381, and the apex394 of each arcuate portion 393 abuts the second surface 343 of thelight guide 342. The arcuate portion 393 maintains a minimum axialspacing between the second surface 343 of the light guide 342 and thefirst surface 355 of the annular wall 381.

At least a portion of the leaf spring 390 is coupled to the annularframe 380. The inner radial edge 384 of the annular wall 381 includesone or more resilient tabs 375 that extend axially in a first direction(i.e., in a direction away from and orthogonal to the first surface 355of the annular wall 381) from the inner radial edge 384. Each resilienttabs 375 has a shoulder 376 that extends radially outwardly from the tab375 toward the first surface 355 of the annular wall 381. Each shoulder376 is axially spaced apart from the first surface 355 of the annularwall 381. The side wall 382 of the annular frame 380 also includes oneor more tabs 378 that extend radially inwardly from an inner surface 383of the side wall 382. The one or more tabs 378 are axially spaced apartfrom the first surface 355 of the annular wall 381. The first surface355 of the annular wall 381 includes one or more protrusions 379 thatextend axially in the first direction from the first surface 355. Aradially outer edge 331 of the central portion 391 of the leaf spring390 is urged axially between tabs 378 and the first surface 355 of theannular wall 381, and a radially inner edge 332 of the central portion391 is urged against the resilient tabs 375, which causes the resilienttabs 375 to bend radially inwardly as the leaf spring 390 passes by theshoulders 376 and is disposed between the shoulders 376 and the firstsurface 355 of the annular wall 381. Also, a concave surface of eacharcuate portion 393 is positioned to face axially toward the firstsurface 355 of the annular wall 381 such that the apex 394 faces awayfrom the first surface 355. The leaf spring 390 defines one or moreopenings 377 that align with the one or more protrusions 379, and theprotrusions 379 extend through the openings 377 when the edges 331, 332are disposed between the tabs 375, 378 and the first surface 355 of theannular wall 381. The tabs 375, 378 hold the leaf spring 390 axially andradially adjacent the annular frame 380, and the protrusions 376 engagedthrough the openings 377 prevent the leaf spring 390 fromcircumferential movement relative to the annular frame 380.

In other implementations, the leaf spring 290, 390 is overmolded with aportion of the annular frame 280, 380 over the central portion 291, 391thereof. And, in some implementations, the spring 290, 390 may beadhered to, snapped to, or otherwise fastened to the annular frame 280,390.

In addition, according to various implementations, the leaf spring 290,390 may comprise a spring steel plate.

The central portion 201 of the touch overlay plate 195 is disposedwithin the opening 185 defined by the inner radial edge 184 of theannular wall 181 and is coupled to the membrane 170, as described above.As shown in FIG. 12 , the first surface 196 of the touch overlay plate195 defines a recessed portion 199 adjacent an outer radial edge 200 ofthe touch overlay plate 195. The recessed portion 199 and an outerradial edge 202 of the central portion 201 of the first surface 196further define a plurality of depressions 203 (or grooves) that extendaxially from the first surface 196 of the central portion 201 to theannular recessed portion 199 and radially inwardly from the outer radialedge 202. To prevent the touch overlay plate 195 from contacting theannular frame 180, the depressions 203 are spaced radially inwardly ofthe radial extensions 204 of the annular wall 181 of the annular frame180. In addition, the distance T_(T) between the surface of the annularrecessed portion 199 and the surface of the central portion 201 isgreater than a thickness T_(A) (as measured in the z- or axialdirection) of the annular wall 181. And, a diameter (or width W_(T)) ofthe second surface 197 of the touch overlay plate 195 is greater than adiameter (or width W_(A)) of the annular wall 181 such that the touchoverlay plate 195 hides the annular wall 181 when the assembly 100 isviewed from the second surface 197 of the touch overlay plate 195.

In some implementations, such as those described above, the distal edge172 of the second wall 106 of the housing 102, the annular frame 180,the light guide 142, and the outer radial edge 200 of the touch overlayplate 195 are generally circular. However, in other implementations,these portions of the switch assembly may have a non-circular shape,such as triangular, rectangular, or other suitable polygonal shape.

In other implementation, the switch assembly includes just one PCB onwhich the force sensors are disposed. In such implementations, thecircuitry required to operate the switch fits on the one PCB.

In addition, in other implementations, the switch assembly may includejust one PCB and one force sensor for applications that require outputfrom one force sensor (output that is not position specific).

In some implementations, the switch assemblies described above aremountable within a vehicle. For example, the switch assemblies aremountable to a steering wheel, such as to the bevel or hub of thesteering wheel, for use in controlling various vehicle systems. In otherexamples, the switch assemblies are mountable to a vehicle door, gearshifter, dashboard, or any portion of the vehicle where input can beprovided and used to control one or more vehicle systems.

For example, in some implementations, such as those described above, thehousing is coupled to a trim piece in the vehicle instead of a frame orsupport portion of the vehicle, which isolates the vibration from thehaptic exciter from other portions of the vehicle. This arrangement alsoallows the gap between edges of the trim piece and the outer edge of theassembly to be minimized because the trim piece can move with theassembly. To couple the housing to the trim piece (or other portion ofthe vehicle), bosses 208 that extend radially outwardly from the outersurface of second wall are aligned with openings defined adjacent theportion of the vehicle to which the switch assembly is being coupled. Afastener is engaged through the aligned openings to secure the assemblyto the vehicle.

FIG. 14 illustrates a block diagram of the electrical control system500, according to one implementation. The electrical control system 500may include a computing unit 506, a system clock 508, and communicationhardware 512. In its most basic form, the computing unit 506 includes aprocessor 522 and a system memory 523 disposed on the second PCB 112.The processor 522 may be standard programmable processors that performarithmetic and logic operations necessary for operation of theelectrical control system 500. The processor 522 may be configured toexecute program code encoded in tangible, computer-readable media. Forexample, the processor 522 may execute program code stored in the systemmemory 523, which may be volatile or non-volatile memory. The memory523, which can be embodied within non-transitory computer readablemedia, stores instructions for execution by the processor 522. Thesystem memory 523 is only one example of tangible, computer-readablemedia. In one aspect, the computing unit 506 can be considered anintegrated device such as firmware. Other examples of tangible,computer-readable media include floppy disks, CD-ROMs, DVDs, harddrives, flash memory, or any other machine-readable storage media,wherein when the program code is loaded into and executed by a machine,such as the processors 522, 532, the machine becomes an apparatus forpracticing the disclosed subject matter.

In addition, the processor 522 is in electrical communication with theforce sensors 140. In some implementations, the system 500 furtherincludes a transceiver that is in electrical communication with theprocessor 522 and one or more vehicle systems. And, in someimplementations, the system 500 further includes a power amplifier 530that is in electrical communication with the processor 522 and thehaptic exciter 160.

However, in other implementations, the system 500 includes two or moreprocessors and/or memories, and the processors and/or memories may bedisposed on the first and/or second PCBs. And, in other implementations,the assembly includes one or more PCBs on which one or more forcesensors, one or more memories, and one or more processors are disposed.

Aspects of the present invention are described above with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems) and computer program products according to implementations ofthe invention. It will be understood that each block of the flowchartillustrations and/or block diagrams, and combinations of blocks in theflowchart illustrations and/or block diagrams, can be implemented bycomputer program instructions. These computer program instructions maybe provided to a processor of a general purpose computer, specialpurpose computer, or other programmable data processing apparatus toproduce a machine, such that the instructions, which execute via theprocessor of the computer or other programmable data processingapparatus, create means for implementing the functions/acts specified inthe flowchart and/or block diagram block or blocks.

These computer program instructions may also be stored in a computerreadable medium that can direct a computer, other programmable dataprocessing apparatus, or other devices to function in a particularmanner, such that the instructions stored in the computer readablemedium produce an article of manufacture including instructions whichimplement the function/act specified in the flowchart and/or blockdiagram block or blocks.

The computer program instructions may also be loaded onto a computer,other programmable data processing apparatus, or other devices to causea series of operational steps to be performed on the computer, otherprogrammable apparatus or other devices to produce a computerimplemented process such that the instructions which execute on thecomputer or other programmable apparatus provide processes forimplementing the functions/acts specified in the flowchart and/or blockdiagram block or blocks.

FIG. 15 illustrates a flow diagram of instructions stored in the firstmemory 523 for execution by the first processor 522 according to oneimplementation. The instructions cause the first processor 522 to: (1)receive a signal from each of the one or more force sensors 140, thesignal being associated with a force received by each of the forcesensors 140, as shown in step 1102, (2) determine a force magnitudeand/or x,y location associated with the received force signals, as shownin step 1104, and (3) communicate the force magnitude and/or x,ylocation to the second processor 532 disposed on the first PCB 110, asshown in step 1106. Having the force sensors 140 in close proximity tothe first processor 522 that initially processes the signals from theforce sensors 140 reduces the likelihood of noise in the signals.

FIG. 16 illustrates a flow diagram of instructions stored in the secondmemory 533 for execution by the second processor 532. The instructionsstored in the second memory 533 cause the second processor 532 to: (1)receive the force magnitude and/or x,y location from the first processor522, as shown in step 1202, (2) identify a haptic feedback responseassociated with the force magnitude and/or x,y location, as shown instep 1204, (3) communicate the haptic feedback response to a hapticexciter 160, as shown in step 1206, and (4) communicate the x,y locationand/or the force magnitude to another vehicle system, as shown in step1208. The switch assembly 100 according to one implementation may beconfigured for controlling up to 32 functions.

The force sensors 140 each receive a portion of the force applied to thetouch overlay 195, and the force received by each sensor 140 isprocessed by the first processor 522 to determine a position andmagnitude of the force applied. The position of the force is determinedby the portion of the force received by each force sensor 140 and theirknown location relative to each other. For example, in theimplementation shown in FIG. 17 , the force received by each sensor 140(shown on the x-axis) is associated with a resistance (shown on they-axis). The position of the applied force is measured in either onedimension (e.g., the x- or y-dimension) or two dimensions (e.g., the x-and y-directions or plane), and the magnitude of the force is measuredin the z-direction. In the implementation shown in FIGS. 1-12 , whichhas four force sensors 140, the position of the force is determined byquad-angulation of the force signals received from each sensor 140. Infurther or alternative implementations, the position of the force isdetermined by tri-angulation using three force sensors. For example, ifone of the four force sensors 140 fails during operation, the locationis determined by tri-angulation using the force signal received from theremaining three sensors 140.

The switch assembly 100 also senses the time that a force is applied ata particular location. For example, the memory 523 may store processingparameters, such as a range of force over time values that indicate aninput signal has been received. Input received outside of the range maybe ignored by the system as unintentional contact with the switchassembly 100. For example, the upper limit of the input range may be 10N of force applied for 20 seconds or less. Furthermore, the switchassembly 100 may also set a force threshold for locking an input area(e.g., 2.5 N) around a location of force input and a second, higherthreshold for a force received within the input area for enabling thesystem 100 (e.g., 3 N). Additional description of force thresholds andvirtual input areas are provided in U.S. Patent Application PublicationNos. 2015/0097791 and 2015/0097795, both published Apr. 9, 2015, whichare included in the Appendix to this application.

In response to the magnitude, location, and/or duration of the appliedforce meeting the input parameters, the switch assembly 100 generates ahaptic and/or audible feedback signal responsive to the detected force.For example, the haptic and/or audible feedback signal may beproportional to the force received. As shown in FIGS. 18A-D, each touchevent (e.g., touch-down shown in FIG. 18A, lift-off shown in FIG. 18B,end of list shown in FIG. 18C, and hold-down shown in FIG. 18D) isinitiated by a different user interaction (e.g., different force valueand/or duration of the touch) and, accordingly, can trigger differenthaptic and/or audible output feedbacks provided to the user. Exemplaryhaptic and/or audible feedback signal responses are described in U.S.Patent Application Publication Nos. 2015/0097794 and 2015/0097793, bothpublished Apr. 9, 2015, which are included in the Appendix to thisapplication.

The drawings illustrate the switch assembly as viewed in an uprightorientation in which the central longitudinal axis A-A is verticallyoriented. However, the orientation shown in the drawings should notlimit how the switch assembly may be oriented within the vehicle. Forexample, in various implementations, the switch assembly is disposed inthe vehicle such that the central longitudinal axis A-A is horizontal orhas a horizontal component relative to the ground.

The terminology used herein is for the purpose of describing particularimplementations only and is not intended to be limiting of theinvention. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theimplementation was chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious implementations with various modifications as are suited to theparticular use contemplated.

The invention claimed is:
 1. A switch assembly comprising: a housinghaving one or more walls that define a chamber; a printed circuit board(PCB) disposed within the chamber, the PCB having a first planar surfacethat faces in a first axial direction and a second planar surface thatfaces in a second axial direction, the second axial direction beingopposite from the first axial direction, the PCB comprising one or moreforce sensors disposed on the second planar surface; at least onesupport surface facing in the second axial direction, the supportsurface being fixedly coupled to the housing, wherein at least a portionof the first planar surface of the PCB engages the support surface; aflexible membrane, the flexible membrane having a first surface thatfaces in the first axial direction toward the second surface of the PCBand a second surface that faces in the second axial direction; and atouch overlay plate, the touch overlay plate having a first surface thatfaces in the first axial direction and a second surface that faces inthe second axial direction, wherein the first surface of the touchoverlay plate is coupled to the second surface of the flexible membrane.2. The switch assembly of claim 1, wherein the one or more force sensorscomprise a plurality of force sensors that are separate and spaced apartfrom each other, and the at least one support surface comprises aplurality of support surfaces that are each axially aligned with arespective force sensor.
 3. The switch assembly of claim 1, wherein theone or more walls of the housing comprise a first wall that extendsorthogonally to the first and second axial directions and a second wallthat extends in the second axial direction from the first wall, thesecond wall having a distal edge that is axially spaced apart from thefirst wall, a plurality of posts extend from the distal edge of thesecond wall in the second axial direction and are circumferentiallyspaced apart from each other, the flexible membrane defines a pluralityof openings, and the posts of the housing extend through the openingsdefined by the flexible membrane.
 4. The switch assembly of claim 3,further comprising a frame having a wall, the wall having an outerradial edge and an inner radial edge, the inner radial edge defining anopening having a central axis extending through the opening, wherein theframe is coupled adjacent the distal edge of the second wall of thehousing such that the flexible membrane is disposed between the frameand the distal edge of the second wall of the housing.
 5. The switchassembly of claim 4, wherein the wall of the frame defines a pluralityof post openings between the outer and inner radial edges of the wall ofthe frame, the post openings being axially aligned with respective postsextending from the distal edge of the second wall of the housing, andthe respective posts extending at least partially through the postopenings of the wall of the frame.
 6. The switch assembly of claim 4,wherein the frame is statically coupled to the second wall of thehousing, and the switch assembly further comprises a spring and a lightguide having a first surface that faces in the first axial direction anda second surface that faces in the second axial direction, the springbeing coupled to the frame and disposed adjacent the second surface ofthe light guide, the spring urging the light guide toward the PCB forpre-loading the force sensors.
 7. The switch assembly of claim 6,wherein the light guide comprises at least two posts that extend axiallyfrom the second surface of the light guide, the light guide posts beingdisposed radially inwardly of the inner radial edge of the wall of theframe, and the spring comprises a leaf spring, the leaf spring having atleast two leg portions engaging distal ends of respective light guideposts.
 8. The switch assembly of claim 1, wherein the first surface ofthe touch overlay plate is adhered to the second surface of the flexiblemembrane.
 9. The switch assembly of claim 1, wherein the switch assemblyis mountable to a steering wheel assembly of a vehicle.
 10. A switchassembly comprising: a housing having one or more walls that define achamber; a printed circuit board (PCB) disposed within the chamber, thePCB having a first planar surface that faces in a first axial directionand a second planar surface that faces in a second axial direction, thesecond axial direction being opposite from the first axial direction; aplurality of force sensors disposed directly on the second planarsurface of the PCB; at least one support surface facing in the secondaxial direction, the support surface being integrally formed with thehousing, wherein at least a portion of the first planar surface of thePCB engages the support surface; a touch overlay plate disposed over theplurality of force sensors, the touch overlay plate comprising a firstsurface disposed facing the plurality of force sensors and a secondsurface opposite the first surface, wherein the touch overlay platepasses a touch force incident on the second surface through to at leasttwo of the plurality of force sensors, and wherein the first surface ofthe touch overlay plate is spaced apart from the second planar surfaceof the PCB; at least one light source disposed directly on the secondplanar surface of the PCB and adjacent the first surface of the touchoverlay plate such that at least a portion of the touch overlay plate isilluminated by the at least one light source; and a haptic exciterconnected to the PCB and vibrationally coupled to the touch overlayplate, wherein the haptic exciter generates at least one of a tactile oraudible feedback that is amplified by the touch overlay plate.
 11. Theswitch assembly of claim 10, wherein at least a portion of the touchoverlay plate is transparent or translucent and the at least one lightsource directs light through the first surface of the touch overlayplate to illuminate the second surface of the touch overlay plate tocreate the illuminated portion of the touch overlay plate.
 12. Theswitch assembly of claim 11, wherein one or more icons are disposedadjacent the illuminated portion of the touch overlay plate.
 13. Theswitch assembly of claim 11, further comprising a light guide, whereinthe light guide is disposed axially between the first surface of thetouch overlay plate and the second planar surface of the PCB.
 14. Theswitch assembly of claim 13, wherein the light guide has a first surfacethat faces the first axial direction, a second surface that faces thesecond axial direction, and one or more side edges that connect thefirst surface with the second surface, wherein light from the at leastone light source enters the light guide from any one or more of thefirst surface and/or the one or more side edges and is directed towardthe second surface.
 15. The switch assembly of claim 14, furthercomprising one or more light altering films disposed adjacent at leastone surface of the light guide.
 16. The switch assembly of claim 10,wherein the at least one light source comprises one or more lightemitting diodes.
 17. The switch assembly of claim 10, wherein theplurality of force sensors change at least one electrical property inresponse to a touch force applied to the touch overlay plate.
 18. Theswitch assembly of claim 10, wherein the plurality of force sensors arecomprised of one or more of a mechanical sensor, a resistive sensor, acapacitive sensor, a magnetic sensor, an optical fiber sensor, apiezoelectric sensor, a silicon sensor, a temperature sensor, amicroelectromechanical (MEMS) force sensor, or combinations thereof. 19.The switch assembly of claim 10, further comprising a processor inelectronic communication with the plurality of force sensors.
 20. Theswitch assembly of claim 19, wherein the processor executes computerprogram instructions for: receiving force information from the pluralityof force sensors about a touch force; and determining from the forceinformation a position of the touch force and a corresponding forcemagnitude, the position identifying a location of the touch force on thesecond surface of the touch overlay plate.